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André Zander

AREVA GmbH

Fourth International Conference on NPP Life Management

October 23rd – 27th, 2017; Lyon (France)

AREVA – Obsolescence and Spare Part ManagementSolutions

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All rights reserved, see liability noticep.24th Conference on NPP Life Management – [email protected] –

Lyon, October 2017 AREVA – AL: [N] – ECCN: [N]

Content

AREVA Aging Management Services and Concepts

Concepts on Obsolescence and Spare Part Management

AREVA’s Pro Active Component Employment (PACE)

Cross Qualification between different Licensing Codes

� Environmental Qualification

� Cross / Delta Qualification

� Commercial Grade Dedication

� Equipment Qualification Database

Summary




Aging Management Scope of Activities Provided by AREVA




COMSY-CivilStructural SSCs

COMSY-ELTElectrical and

I&C-Components

Rotating Machine

Monitoring SystemsDIROM, SÜS, FAMOS,

ADAM/SIPLUG, etc.

COMSYCondition Oriented Lifetime

Management System

APOTSAREVA Plant Obsolescence

Tracking Services

COMSY-MECMechanical components

Aging Management AREVA - COMSY Software platform




Experience has shown that many NPPs repeatedly encounter the problem that

required components and systems are no longer available because they have

been discontinued

An efficient and optimized Obsolescence Management serves to avoid production

downtime due to absolute or not longer available spare parts.

Reasons for obsolescence might be:

� OEM or OCM is no longer active on the market

� Knowledge is no longer available or has been lost

� Components or assemblies have been discontinued or modified by the manufacturer

� Economic obsolescence (cost of component or repair is to high)

Obsolescence and Spare Part Management

“Obsolescence is unavoidable and cannot be prevented but visionary and

careful planning can minimize its effects and its potential high costs.”

DIN 62402:2007




Obsolescence Management ConceptReactive vs. Proactive

AREVA recommends for safety and availability relevant SC

Proactive Obsolescence Management




The life cycle status analysis (LCSA) is the key element of each proactive

obsolescence management.

The main task of a LCSA consist of evaluating and monitoring of the

availability of systems and components (SC) in a timely manner.

For each considered component a life cycle status and procurement source

are specified and if possible the point in time at which the component is

expected to be still available on the market.

Operators are then informed in a timely manner by way of notices of

discontinuation and change that refer to these components, and can then

act accordingly.

Obsolescence Management ConceptsProactive Obsolescence Management

PRODUCT LIFE CYCLE PHASES




AREVA – Different levels of services

In times of economic challenges, the service needs to be

limited to the lowest necessary cost

1. Spare parts Procurement

• Spare parts sales and Engineering

• Quality management (incl. Supplier requalification, production supervision)

• Packing - Shipping - Custom clearance

2. Reports on part availability (PACE)

3. Check and approval of manufacturing documents by accredited

inspection authority

4. Qualification and Auditing of new/alternative manufacturers

5. Spare part engineering support = Identify alternative solutions including

spare parts repair

6. Cross-qualification

7. Commercial grade dedication

8. Re-engineering

Ob

sole

sce

nce

se

rvic

es

Sp

are

pa

rts

costs

PACE – PRO ACTIVE COMPONENT EMPLOYMENT




Commercial RelationshipsPotential for Cost Reduction by Bundling Obsolescence

Management

NPP C

Supplier e

Supplier d

Supplier c

Supplier b

Supplier a

NPP B

NPP A

•

•

•

•

•

•

AREVA proposes a synergetic approach to obsolescence management

Synergies

• Approved vendor‘s list

• VGB audits

• Supplier qualification and

management

• Contracts & negotiation

• Planning certainty for NPPs

and Suppliers

• Improved negotiation

position

• Effective processes and

interfaces

• Valorization of AREVA’s OEM

situation

• Bundling for EPR & Gen III

projects

• Valorization of AREVA

products (MLI)

5 + 3 = 8 relations




Customer Need & AREVA Scope of SolutionsCustomer Needs Overview

AREVA is capable to address needs from both operators and nuclear industry

suppliers, and benefit from the complementarity between these two markets.

AREVASpare parts and

obsolescence

solutions

Suppliers

Access to nuclear

market

Sales on nuclear

market

Operators

Spare parts Obsolescence

Spare Part

Procurement

• Ad-hoc

• Insurance of

future

availability

Repair

Cross-qualification or

commercial grade

dedication

Re-engineering

Service for outdated equipment

Operation know-how

and trainingConsulting

• Identify

challenges: which

parts, when?

• Monitor suppliers

• Studies: repair or

replace?

Supplier availability and qualification

assessment

Trustful and

dependable

relation

Trustful and

dependable

relation

AREVA as a sales

agent and partner in

a difficult market

Price level on nuclear market > 50% higher

with limited additional costs

Bridge to bring

industrial products

on nuclear market

Reliable and loyal customer with stable

demand and price

Qualification of sub-

sub-suppliers

Legal certainty

Branding effect by

being qualified

AREVA supplier

Consulting (nuclear qualification, audit

preparation)

Customer Need that can potentially be addressed by AREVA

Guarantees on these services




Spare PartRisk Level Evaluation

Severity• 1. = time for procurement of the spare < 15 days,

• 2. = 15 days < procurement of the spare < 2 months,

• 3. = 2 months < procurement of the spare < 6 months part time ,

• 4. = procurement of the spare > 6 months

1 2 3 4

low1

2

3

4

medium

high

critical

Risk• 1. = very little chance to happen,

• 2. = probability that it doesn't happen > probability it happens,

• 3. = probability that it doesn't happen < probability it happens,

• 4. = very likely




A probabilistic approach can be used to calculate the required spare parts of a

particular component for a certain period of time

The calculation is based on the faulty part or component being replaced by a spare

part and no repair is carried out on site. For this purpose the use of a Poisson

distribution has become an generally recognized approach in the industry.

Obsolescence Management ConceptsCalculation of Required Spare Parts



Lyon, October 2017 AREVA – AL: [N] – ECCN: [N]8

The APOTS software:

� tracks information of life cycle for

every part “Available”, “Last-Time

Buy”, “Product Cancellation”, L

� calculates the meantime between

failure and recommends the part

stocking levels

� tracks the inventory part list and

availability

� forecasts depletion dates of

available

spare parts

PACE

SOFTWARE SERVICES

The PACE service:

� Tracking of information of life cycle for

every part

� Tracking of suppliers qualification

status and NPP inventory part list per

system

� Identify all parts that the OEM no

longer manufactures and has been

declared obsolete (product

discontinuation)

� Periodically update with OEM Last-

Time Buy (LTB) obsolescence notices

(Available, Last-Time Buy, Product

Cancellation, Obsolete)

Methods in detailReports on part availability (PACE)

AREVA-Support in Cross Qualification between different Licensing Codes




AREVA Environmental Qualification Services Introduction

Performing of Environmental Qualification tests according to all standards

e.g. IEEE / RCC / US NRC 10CFR50, Appendix B, ANSI – ASME NQA-1 / KTA

Preparation and performance of the complete test program

� Preparation of test programs and specification in cooperation with customer

� Performing of qualification test, preconditioning and accident tests

� Handling of test specimens and preparation of auxiliary systems

� Planning and supply of measurement equipment

Wide range of standard measurement devices available, e.g. insulation or loop

resistance measurement, torque, high voltage etc.




AREVA Environmental Qualification Services – Example: Test Sequence for Valve Actuators based on KTA 3504

Preconditioning (‚Aging‘) Simulation of Accident Tests




Introduction – Costumer Needs

NPP

NPP

start up

End of

operating

license

Erection

Phase

Costs

Some certified suppliers are quitting the nuclear market

Possible Alternatives

Cross-qualification of existing equipment from alternatives supplier

Re-qualification of equipment from new supplier

Re-engineering of equipment and components




Cross Qualification - Background

► Cross qualification including commercial grade dedication (if applicable)

offers an optimum solution in transferring existing standards of a pre-qualified

product to other requested standards taking into consideration product

functionality, quality and qualification aspects.

► Any gaps after analysis are documented, closed and the product is supplied.

► AREVA carries out

cross qualification

between major standards

e.g. KTA, ASME, RCC-E/M,

IEEE, etc.




Benefits of Cross Qualification

� Reduces cost of qualification (supplier and equipment)

� Shortens lead time of alternative spare parts supply of obsolete parts

� Avoids major component replacement

� Avoids spare part obsolescence for safety classified systems

� All in one hand: AREVA leads and guides all actions of delivering a certified product

� Reliable and experienced partner in cross qualification

NPP operators worldwide have challenges with component aging,

obsolescence issues and the need to replace components although

some certified suppliers are quitting the nuclear market.




AREVA’s Codes & Standards CompetenceCodes & Standards applied for EPRs – BNI – Example OL3

� For EPR Olkiluoto and China for BNI part Specification concept was widened

� Application of ASME or KTA 3211 or RCC-M

� Component specifications were created for class 2 based on this approach

RCC-M applied for

� Primary Components

� Valves, Piping Cl. 1+2

� Pumps Cl. 1+2

ASME applied for

� Pressure Vessels Cl. 2

KTA applied for

� Incore Instrumentation

� HX, Filters, Pumps Cl. 2

Harmonized standards

� Class 3 and NC Comp.

� Piping, Valves, Tanks,

HX, Pumps, Filters,

Waste System

Components, Others




Example for Environmental Test Conditions KTA – IEEE – RCC-E

Technical Comparison – Environmental Test Conditions :

p,T,H

� KTA – specific for KWU designed PWR 1300 NPPs

1) Pre-stress tests (ageing simulation)

� Temperature 3C < T < 70C cycle

� Cycletime 24h / Test time 2000h

� Radiation 0.5kGy/h � 50kGy

2) p/T/H – test

� T > 150C (1h)

� p ~ +1.1 bar (1h)

� H > 95% rel

� DT ~ 24h

3) Radiation in Service

� dr = 200kGy

� dtr = 0.5kGy/h

4) Post accident

� Temperature 70C

� H > 95%




Technical Comparison – Environmental Test Conditions :

p,T,H

� IEEE – NPP independent qualification specification – generic approach

� Test curve is individual per equipment with respect to required

Temperature and Pressure values – shape of curve is comparable

Margin Type a) Margin Type b)





Technical Comparison – Environmental Test Conditions : p,T,H

� RCC-E – specific for French NPP fleet (used in FA3 / TSN / UK-HPC)


1) Pre-stress tests

(ageing simulation)

� Temperature 70C

� Radiation 1kGy/h

2) p/T/H – test

� T = 156C (~50h)

� p ~ +4.6 bar (~20h)

� H > 95% rel

� DT > 300 h

Two thermodynamic

shocks applied




Example: Pressure transmitter

Pressure transmitter

� In A2 Hartmann & Braun Scope

� Hartmann & Braun does not exist anymore and no successor exists

� Three diverse CFI equipment are required

• formerly supplied by H&B, SIEMENS, Fischer

� A2 Keys T11x, T21x, T22x

� Possible alternative: Ultra Electronics DTN2070

� Qualified according to IEEE 323-1974

Environmental Qualification and IEEE 344-1987

Seismic Qualification

Example:

JEA10CL052




Example: Pressure transmitter

Pressure transmitter with remote seal

� In A2 Hartmann & Braun Scope

� Hartmann & Braun do not exist anymore and no successor exists

� No KTA qualified remote seal device available

� A2 Keys T11VE/T11V+, T22TE/T22T+

� Possible solution: Rosemount 3159 +3152

� Qualified according to IEEE 323 – 1974/1983/2003

and IEEE 344 1975/1987/2004

Example:

JNK10CL052




Level Transmitter

Level Switch in harsh environment

� In A2 Endress+Hauser Scope

� Endress+Hauser do not produce nuclear type tested equipment

anymore

� A2 Keys to be replaced: L4xx (e.g. L438)

� Possible alternative: FLT93 supplied by FCI

� Qualified according to IEEE 323 1983 and IEEE 344-1987

Example:

JNA10CL051




AREVA Commercial-Grade Item Process

The “Commercial grade dedication” is a process

which enables to use a component without nuclear

qualification into a nuclear safety related application

� This acceptance process show that the component

will perform its intended safety function equivalent to

an item under e.g. 10 CFR Part 50, Appendix B,

quality assurance program.

� It is achieved by identifying the critical characteristics

of the item and verifying their acceptability by e.g.

manufacturing inspections, tests or analyses

(including actions/requirements in response to e.g.

NRC Generic Letter 89-02 and 91-05)

AREVA has the experts on the specific fields to perform these

sophisticated process




Equipment Qualification Data Base (EQDB)

AREVA EQDB provides

access to pre-qualified listings

including Electrical, I&C and

active mechanical equipment

The amount of pre-qualified

equipment will continuously

increase due to the need of

Qualified Equipment for

AREVA’s worldwide projects

and the on-going incorporation

of qualified equipment of

former AREVA projects.

Saving Cost and Time by using Pre-Qualified Equipment




AREVA provide

� Obsolescence and

� Spare part support

to worldwide customers (with various plant designs)

Obsolescence and Spare Part ManagementOperating Experience

� Argentina

� Brazil

� Spain

� USA

� France

� Germany

� Swiss

� South Africa

� China

� et al.

Several plants have Long-Term Framework

Agreements to optimize cooperation

AREVA NP

4th Conference on NPP Life Management – [email protected] –


Obsolescence and Spare Part ManagementSummary

OUR SOLUTION

CUSTOMER ISSUE

16

The nuclear power plant (NPP) fleet is ageing and some units will engage lifetimeextension programs.

Many NPPs repeatedly encounter the problem that specific components andsystems are no longer available because they have been discontinued.

AREVA NP’s Pro Active Component Employment (PACE) avoids plant downtimedue to obsolescence issues

Strong Technical Support - Experience in Nuclear, Technical and QualityRequirements (Safety-Related procurements)

Assures qualified products and spare parts for obsolete components on time

Evaluation of optimal customized obsolescence solutions e.g. procurementengineering, cross-qualification, commercial grade dedication and re-engineering

Keeps production and service time at a high level

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